Electrical vehicles have existed since the late 1800s but were overtaken by gasoline vehicles in the early 1900s due to gasoline becoming more powerful and cheaper. There are now renewed interests in electrical vehicles due to environmental concerns. There are battery electric vehicles (BEVs) which run solely on batteries, and hybrid electric vehicles (HEVs) which combine an electric motor with a combustion engine or other power source. HEVs can achieve emissions reductions of 50-92% compared to gasoline vehicles. Key technologies for electrical vehicles include lithium-ion batteries, fuel cells, and electric motors powered by advanced power electronics and control systems.
Electrical vehicles have existed since the late 1800s but were overtaken by gasoline vehicles in the early 1900s due to gasoline becoming more powerful and cheaper. There are now renewed interests in electrical vehicles due to environmental concerns. There are battery electric vehicles (BEVs) which run solely on batteries, and hybrid electric vehicles (HEVs) which combine an electric motor with a combustion engine or other power source. HEVs can achieve emissions reductions of 50-92% compared to gasoline vehicles. Key technologies for electrical vehicles include lithium-ion batteries, fuel cells, and electric motors powered by advanced power electronics and control systems.
Electrical vehicles have existed since the late 1800s but were overtaken by gasoline vehicles in the early 1900s due to gasoline becoming more powerful and cheaper. There are now renewed interests in electrical vehicles due to environmental concerns. There are battery electric vehicles (BEVs) which run solely on batteries, and hybrid electric vehicles (HEVs) which combine an electric motor with a combustion engine or other power source. HEVs can achieve emissions reductions of 50-92% compared to gasoline vehicles. Key technologies for electrical vehicles include lithium-ion batteries, fuel cells, and electric motors powered by advanced power electronics and control systems.
Electrical vehicles have existed since the late 1800s but were overtaken by gasoline vehicles in the early 1900s due to gasoline becoming more powerful and cheaper. There are now renewed interests in electrical vehicles due to environmental concerns. There are battery electric vehicles (BEVs) which run solely on batteries, and hybrid electric vehicles (HEVs) which combine an electric motor with a combustion engine or other power source. HEVs can achieve emissions reductions of 50-92% compared to gasoline vehicles. Key technologies for electrical vehicles include lithium-ion batteries, fuel cells, and electric motors powered by advanced power electronics and control systems.
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Electrical Vehicles
Dr.ir. Johan Driesen
overview • history • technology • why drive “e” ? – car types • what can be – drive system • motor achieved ? • power electronics • outlook • control system – energy storage/production – driving style
J.Driesen - Electrical Vehicles
1 history: 1895-1910 • electric vehicles were the most promising drive technology end 1800’s: speed records, neater cars • combustion engine took over in early 1900’s: became more powerful, easy to take with cheap fuel J.Driesen - Electrical Vehicles
Janetzy Jamais Contente
• first car ever to exceed 100 km/h – 24/04/1899 – 105.882 km/h – 2 electric motors in ‘aerodynamic’ car – driven by Camille Janetzy (B.) in Achères (Fr.) – named “Jamais Contente” J.Driesen - Electrical Vehicles
2 history: 1905-1925 • gasoline vehicles take over completely: discovery of many oil wells drop fuel prices • mass production techniques introduced by Ford • short revivals: – Edison battery (NiFe) – WW I: oil shortage • 1900 US car production: 1575 electric cars vs. 936 gasoline cars down to 4% in 1925 J.Driesen - Electrical Vehicles
history: after WW II • 60s: small ‘smog buster’ cars – GM 512, Ford Comuta (failed to sell: smog reduction incentive too limited) • 1973: oil crisis – economical push to revive EV R&D as a mean to reduce oil dependence • 80s: growing environmental concerns – Clean Air Acts (California) and other • 90s: evolution in power electronics J.Driesen - Electrical Vehicles
3 EV types • BEV: battery-electric vehicle – rechargeable batteries ONLY source (storage) of energy • HEV: hybrid electric vehicle – electrical energy storage plus onboard means of power generation, which may be converted into electricity – additional diesel, gasturbine, fuel cell
J.Driesen - Electrical Vehicles
noxious emissions • ‘zero-emission vehicle’ (ZEV) in fact does not exist ! • emissions MUST be considered over entire energy cycle, including power plants – reference: traditional combustion drive – battery vehicles need to be charged with electricity produced elsewhere: yet, in total only 1/10 of emissions – hybrid vehicles can reach 1/8 of emissions (just clean enough ?) J.Driesen - Electrical Vehicles
4 emissions: detail • Full cycle (B)EV compared to CV – CO: -99%, HC: -97%, NOx: -92%, CO2: -50% • EV emissions continuous; no peak emissions in ‘cold starts’ and short trips • hybrid emissions close to BEV levels: just clean enough • fuel cells: emissions almost eliminated
J.Driesen - Electrical Vehicles
internal-combustion engine characteristics • internal combustion engine: bad efficiency characteristics • size determined by peak power • gears necessary • fuel efficiency: 18% (46 % electric) J.Driesen - Electrical Vehicles
5 enhance efficiency • enhance efficient use of combustion engine – use a second drive (electric) to stay in point of maximum efficiency – size determined by peak power demand: shave the peak with electric motor – bring own energy source to produce (some of) the electricity • different philosophies leading to hybrid cars
J.Driesen - Electrical Vehicles
HEV types • series HEV • parallel HEV – engine powers – engine delivers generator mechanical energy – generator charges to drivetrain directly batteries and/or – electric motor supplies motor (generator) on directly drivetrain as well – purely electrical interface to drivetrain
J.Driesen - Electrical Vehicles
6 HEV types: power system architecture
J.Driesen - Electrical Vehicles
series HEV • ‘extend BEV with onboard charging’ • switch off engine (BEV mode) for short trips or to drive clean • energy production and driving are decoupled • simple mechanical drive (no gears) J.Driesen - Electrical Vehicles
7 parallel HEV • keep engine in optimal operation • use motor while accelerating • use as generator while decelerating • engine can be very small • complex mechanical train J.Driesen - Electrical Vehicles
alternative HEVs • fully decoupled • series/parallel: complicated
J.Driesen - Electrical Vehicles
8 hybrid car layout
J.Driesen - Electrical Vehicles
Hybrid driving: starting
J.Driesen - Electrical Vehicles
9 Hybrid driving: driving
J.Driesen - Electrical Vehicles
Hybrid driving: Acceleration
J.Driesen - Electrical Vehicles
10 Hybrid driving: deceleration & braking
J.Driesen - Electrical Vehicles
Hybrid driving: charging
J.Driesen - Electrical Vehicles
11 Hybrid driving: stopping
J.Driesen - Electrical Vehicles
HEV: non-electrical parts
• ‘engine’ with • energy storage rotating output – batteries – diesel: kept in – flywheel optimal operation – supercapacitors point – high-speed gasturbine • ‘engine’ with electrical output – fuel cell J.Driesen - Electrical Vehicles
12 flywheel storage • major problem: gyroscopic effects – difficult to manoeuvre, overturn danger – use special fixture
J.Driesen - Electrical Vehicles
battery types • Pb-acid: cheap, low • NiMH, Li-Ion: high performance densities, long life, • NiCd: reliable, high charge/discharge ‘memory effect’, rates, safe, no environmental maintenance, problems (Cd) pollution-free • NaS, NaNiCl: operate above 300°C, dangerous, not flexible • NiZn: small number of load cycles
J.Driesen - Electrical Vehicles
13 batteries: overview
Properties of the main battery types.
Pb-Acid NiCd NaNiCl NiZn NiMH LiIon
specific energy [Wh/kg] 35 50 90 55 60 120 energy per volume [W/A] 80 85 140 130 125 200 specific power 120 130 150 150 165 230 (*)[W/kg] cycle life (**) 800 3000 1500 300 > 600 600 operating temperature ambient ambient 300º C ambient ambient ambient (*) peak power density at 80% DOD (depth of discharge) over 30 s (**) cycle life (80% of initial capacity)
J.Driesen - Electrical Vehicles
fuel cells • controlled oxidation reaction: direct conversion of chemical energy into electrical energy (DC) • run on pure H2 or H2-rich reformed methane, methanol, ethanol or gasoline • store gaseous fuel in pressure cylinder or metal hydride tank • higher efficiency than combustion-based: no Carnot-limit • different types, polymer electric membrane fuel cell (PEMFC) most promising J.Driesen - Electrical Vehicles
pure battery EV • emissions are moved to (more efficient) power plants • need recharging stations • recharging = slow • recharge overnight (cheap power) • batteries are heavy and spacious • extremely silent
J.Driesen - Electrical Vehicles
15 true ZEV: solar challenge cars • regular race for photovoltaic powered cars: in Europe, Australia • extreme efficiencies required
J.Driesen - Electrical Vehicles
powering up • filling up a classical car with gasoline is the equivalent of an MW energy transfer • using an electrical cable: tens filling up a hybrid of kW (need several hours) (trailer system)
16 electrical motor types • DC machines: brush problems • induction machines with cage rotor • synchronous machine types – permanent-magnet machine, ‘brushless-DC’ – reluctance machine: simple but limited efficiency and performance, noisy – hybrid machines (mixed types, e.g. with additional cage): complicated design and construction J.Driesen - Electrical Vehicles
electrical motor location(s)
• large central motor and mechanical distribution • motor per wheel – external motor – special motor design built-in wheel (direct drive) – 2- and 4-wheel drive schemes possible using fast (digital) control systems
J.Driesen - Electrical Vehicles
17 field weakening • higher speeds: induced voltages increase – need more insulation – power electronics must be capable to handle high voltages • lower field or introduce ‘anti- field’ • result: higher speed in exchange for lower torque, but keep power and losses constant • use for cruising: high speed on highway, but no more vigorous accelerations (‘overdrive’ gear)
J.Driesen - Electrical Vehicles
DC-machine • simple to control, simple power electronics (DC/DC with choppers) • easy field weakening in shunt machines • maintenance of brush/collector • outperformed by all other motor types
J.Driesen - Electrical Vehicles
18 induction machines • special construction for use with inverter • advanced inverter and control, especially at low speeds • field weakening possible for cruising • significant rotor losses in cage: difficult to cool • limited efficiency J.Driesen - Electrical Vehicles
permanent-magnet synchronous machine • same inverter, but slightly simpler control compared to induction machine • difficult flux weakening for cruising • temperature sensitive permanent magnets: reversible and irreversible demagnetisation • only significant stator losses • different designs J.Driesen - Electrical Vehicles
19 motor types: examples • induction machine
• permanent magnet synchronous machine
J.Driesen - Electrical Vehicles
(switched) reluctance machine • synchronous machine without field winding nor permanent magnets • torque due to Xd/Xq difference • simple construction • noisy, vibrations
J.Driesen - Electrical Vehicles
20 direct wheel drives • usually PMSM with high number of poles, integrated into (four) wheels, special magnetic design • direct braking as well • difficult control to maintain synchronism between wheels, go through curves: ‘differential axle in software’ J.Driesen - Electrical Vehicles
motor cooling • use water cooling to prevent insulation damage and demagnetisation
Water cooled HEV
mini-van motor (ESAT/ELEN design)
J.Driesen - Electrical Vehicles
21 power electronic circuits • several base circuits necessary, with own (coordinated) control – DC/DC (chopping) with battery or fuel cell to deal with changing DC voltage level – AC/DC (active rectifier) with generator on diesel/gasturbine for rectification – DC/AC based on PWM for AC motor supply • components: IGBTs • use special circuits to limit the (switching) losses and increase performance (high dynamism) • voltage as high as possible to minimize losses (500 V)
J.Driesen - Electrical Vehicles
electrical drive: scheme
J.Driesen - Electrical Vehicles
22 electrical drive: detail
J.Driesen - Electrical Vehicles
4-wheel direct drive control
J.Driesen - Electrical Vehicles
23 car control systems • implement control system in powerful digital signal processors (DSPs) • driver gives linear speed reference, but mimic feel of traditional gas pedal (non- linear control of injected power/fuel) using digital filters • easy implementation of systems such as ABS, traction control and cruise control in DSP software J.Driesen - Electrical Vehicles
car operation • using advanced control and power electronics optimal performance (maximum torque) at every speed from 0 km/h to top speed • totally gearless (except some hybrids) • beyond ‘maximum torque speed’: cruising using controlled field weakening J.Driesen - Electrical Vehicles
cycle, based on points in city driving cycle measurements J.Driesen - Electrical Vehicles
F3 on race track • typical driving cycle • electrical F3: of F3 (Donington comparable circuit, UK) performance
J.Driesen - Electrical Vehicles D. Howe: University of Sheffield
25 regenerative braking • EV powertrains are reversible – motor becomes generator – batteries/flywheels are recharged • 60% of energy spent in urban driving is used for inertia effects (acceleration) • braking/deceleration: recovery of about half of this energy could be possible J.Driesen - Electrical Vehicles
power system architecture
design • typical design values – fuel economy: min. 35 km/l (3* better!) – range: 612 km – acceleration 0-100 km/h in 12 sec. – max. speed 140 km/h – 6.5 % climb at 90 km/h for 20 min. – drive away in 5 sec., full power after 2 min. – meet emission standards – price of family sedan J.Driesen - Electrical Vehicles
commercial (H)EVs • Traditional companies • EV-only companies – GM EV-1, S10 pickup – Tzero – Toyota Prius I & II, RAV4-EV – Solelectrica – Honda EV-plus, Insight – Enova systems – Daimler Chrysler Epic – Orion – Ford Ranger EV – … – Nissan Altra, Tino – ...
J.Driesen - Electrical Vehicles
27 why doesn’t it sell (yet) ? • societal concerns: – pollution of environment – noise, dangerous petrochemicals • personal concerns – cheap in investment and use – comfortable (e.g. noise) • fail on price argument: electric vehicle are cars for “Greens with greens”
